Polyamide-imide resins

ABSTRACT

A POLYAMIDE-IMIDE RESIN (AND THE POLYDIAMIDE-MONOCARBOXYLIC ACID PRECURSOR) CONTAINING AT LEAST ONE AMIDO GROUP WHICH IS NOT PART OF THE AMIDE-IMIDE POLYMERIC UNIT, AND TO THE USE THEREOF AS ELECTRICAL INSULATION. THIS IS EXEMPLIFIED BY POLYAMIDE-IMIDES DERIVED FROM TRIMELLITIC ANHYDRIDE OR AN EQUIVALENT AND AN AROMATIC TYPE POLYAMINE CONTAINING AT LEAST ONE AMIDO GROUP WHICH IS NOT PART OF THE AMIDE-IMIDE POLYMERIC UNIT.

United States Patent Ofi ice 3,554,984 POLYAMIDE-IMIDE RESINS Norman J. George, St. Louis, Mo., assignor to The P. D. .George Company, St. Louis, Mo., a corporation of Delaware No Drawing. Continuation-impart of application Ser. No. 423,331, Jan. 4, 1965. This application Oct. 16, 1968, Ser. No. 768,164

Int. Cl. C08g 20/32 U.S. Cl. 260-78 8 Claims ABSTRACT OF THE DISCLOSURE A polyamide-imide resin (and the polydiamide-monocarboxylic acid precursor) containing at least one amido group which is not part of the amide-imide polymeric unit, and to the use thereof as electrical insulation. This is exemplified by polyamide-imides derived from trimellitic anhydride or an equivalent and an aromatic type polyamine containing at least one amido group which is not part of the amide-imide polymeric unit,

This application is a continuation-in-part of application S.N. 423,331, filed Jan. 4, 1965, now US. Pat. No. 3,428,486, granted on Feb. 18, 1969.

This invention relates to a polyamideimide resin (and the polydiamide-monocarboxylic acid precursor) containing at least one amido group which is not part of the amide-imide polymeric unit, and to the use thereof as electrical insulation. This is exemplified by polyamideimides derived from trimellitic anhydride or an equivalent and an aromatic type polyamine containing at least one amido group which is not part of the amide-imide polymeric unit.

This invention relates to resins and combinations of resins and to their use in electrical insulation. More particularly, this invention relates to electrical insulation, to electrical conductors containing in combination a base insulation coat and an over insulation coat, said overcoat being a polyamide-imide resin.

Synthetic resins suitable for use as electrical insulating materials, particularly materials which are satisfactory for use as slot insulation in dynamoelectric machines and for use as insulation for conductors which are to be employed as magnet wires (insulated electrical conductors) in electrical apparatus must be able to withstand extremes of mechanical, chemical, electrical and thermal stresses. Thus, wires to be employed as coil windings in electrical apparatus are generally assembled on automatic or semiautomatic coil winding machines which, by their very nature, bend, twist, stretch and compress the enameled wire in their operation, After the coils are wound, it is common practice to coat them with a varnish solution containing solvents such as ketones, alcohols, aliphatic and aromatic hydrocarbons, halogenated carbon compounds, etc. Magnet wire insulation must be resistant to these solvents. In order to conserve space in electrical apparatus, it is essential that the individual turns which make up the coils be maintained in close proximity to each other. Because of the closeness of the turns and the fact there may be a large potential gradient between adjacent turns, it is necessary that the resins employed as wire enamels have high dielectric strength to prevent short circuiting between adjacent coated wires. In the operation of electrical apparatus containing coiled wires, high temperatures are often encountered and the enamels must be I able to withstand these high temperatures as Well as the 3,554,984 Patented Jan. 12, 1971 Although a wide variety of synthetic resins have been prepared which are adaptable for use as insulation for electrical conductors such as for use as magnet wire insulation, the insulated wire is often deficient in one or more of the properties desired in the insulated wire.

Recently there have been developed certain polyamideimide resins suitable for electrical insulation which are derived from (1) trimellitic anhydride, trimellitic acid or their equivalents and (2) diamines which resins possess good high temperature properties. However, when these resins are applied to an electrical conductor such as a magnet wire and cured they have been found to be deficient in many properties. For example, a commercial polyamide-imide resin, Amoco Chemical Company A1 Type 10, applied to a magnet wire and cured yields a wire enamel which has poor runability, poor Emerson scrape, poor dielectric properties and poor adherence.

I have now discovered that one can avoid the deficiencies which are present when polyamide-imide resins, derived from trimellitic acid or its anhydride and diamines, are applied directly to electrical conductors such as magnet wires by (l) first applying and curing a base polyester coat on the conductor and (2) then applying to the base coat and curing an over coat of a polyamide-imide polymer of a trifunctional carboxylic acid or its equivalent, such as trimellitic anhydride (TMA), trimellitic acid or their equivalents, and a diamine.

The results are surprising in view of the fact that whereas the cured polyamide-imide resin Wire enamel applied directly to the wire has poor runability, poor Emerson Scrape, poor dielectric properties and poor adherence, a wire enamel containing the combination of a polyester base coat with a polyamide-imide overcoat among other things has good runability, good Emerson Scrape, good dielectric properties and good adherence.

Stated another way, the combination of a polyester base coat and a polyamideimide over coat upgrades the usefulness of polyamide-imide resins by converting them from poor to superior wire enamels. In addition the combination improves the characteristics of the polyester resin base coat.

Polyester resins are too well known to require an elaborate discussion thereof. However, they will be illustrated by the following discussion. Thermosetting polyester resins used for wire insulation are of various forms but commonly are generally characterized as the reaction products of a polyhydric alcohol, a glycol and a dicarboxylic acid or a lower alkyl ester thereof, the resin being commonly cured with a suitable catalyst, such as a metal catalyst, salts thereof, etc. such as zinc, titanium, litharge, lead, etc. Such resins have shown remarkable thermal stability when measured in accordance with standard procedures in the electrical industry. Moreover, they are readily soluble in organic solvents and can be applied to electrical conductors such as copper or aluminum wire by conventional coating methods followed by curing a high temperatures such as for example 500- 1000 F.

Examples of polyester resins of the type described, which have been used to advantage for magnet wire insulation, are:

(1) An ester of a phthalic acid such as terephthalic or isophthalic acid reacted with polyols such as glycerine and/or pentaerythritol plus small quantities of silanes or siloxanes, and 1 (2) Esters of phthalic acids such as terephthalic or isophthalic acid reacted with a polyol such as (a) glycerine or pentaerythritol and the like, and (b) a glycol such as ethylene glycol, 1,4-butane diol or a mixture thereof, and the like.

These various polyesters are disclosed, for example,

in US. Pat. 2,686,739, dated Aug. 17, 1954; 2,686,740, replaced in whole or in part by isocyanuric derivatives. dated Aug. 17, 1954; 2,889,304, dated June 2, 1959; and For example, esters of this type are prepared from (1) 2,936,296 dated May 10, 1960 and e sewhere. Other a phthalic acid or ester thereof preferably isoor terpolyester formulations which are suitable for insulation ephthalic ester (2) ethylene glycol and (3) tris (2-hyare described in Alkyl Resin Technology, Patton droxyethyl) isocyanurate. Modifications thereof are dis- (Interscience Publishers 1962). These patents and pubclosed in these patent applications.

lications are, by reference, incorporated into this applica- The over coat of polyamide-imide resin is characterized tion as ifapart thereof. by having recurrent units from a diamine and a tri- Certain modified polyester resins of the thermosetting carboxylic acid, such as trimellitic acid, its anhydride or type have also been so used. These are produced by addequivalents for example of the formula ing to the dihydric and polyhydric alcohol-phthalate O polyester in essentially linear form a substantial pro- IL portion of another reactant, such as an isocyanate of H the more thermally stable type, which serves as the RN predominant cross-linking agent in curing the resin on the conductor. One such isocyanate commonly used for this ll purpose is the trimer of a trisubstituted phenol or cresol blocked cyanuric acid such as Mondur SH, a product where is a moiety of the tricarboxylic acid, preferably of Mobay Chemical Company, Pittsburgh, Pa., having having benzenoid unsaturation, and R is a moiety of the following structural formula: the diamine containing at least two carbon atoms, pref- CH:1 Ilene-(PG These isocyanates (such as Mondur SH) tend to imerably having benzenoid unsaturation. Stated another prove thermal stability, reduce heat and solvent shock way, these polymers are polyamide-imides of tricarboxylic and, because of their active cross-linking, harden and acids or their equivalents, and diamines. toughen the finished film as well as improve its electrical The organic diamines usable in this invention are those properties. Other blocked isocyanates besides Mondur having the structural formula H NR'-NH wherein SH have also been employed. These are well known to R, a divalent radical containing at least 2 carbon atoms, the artmay be aromatic, aliphatic, cycloaliphatic, a combination These prior polyester resins of particular utility in the of aromatic and aliphatic or substituted groups thereof, present invention can be described as thermosetting polyetc. The most useful diamines are the primary diamines esters or modified polyesters which are either (a) the which, upon reaction with the trifunctional acids may cured reaction product or both diand polyhydric provide polyamide-acids which are then converted into alcohols and a dicarboxylic acid or its ester (generally the polyamideimides. The preferred R groups in these an ester of isoor terephthalic acid) or (b) formed by diamines are those containing at least six carbon atoms adding to the components included under (a) above, in and characterized by benzenoid unsaturation. More linear polymeric form, a cross-linking reactant such as an isocyanate of the type described above, and curing the resin with this additional reactant. More briefly, they may be described as thermosetting polyester or modified polyester resins of the dihydric alcohol-polyhydric alcohol-dicarboxylate type. The inclusion of a metal catalyst specifically these groups are:

in the resin solution, such as zinc, lead, titanium, etc., and the like, Where is Carbon, nitrogen, y Silitends to promote cross-linkage and increase the cure P p of p rate. Among the diamines which are suitable for use in the Another particular class of polyester resins are de- Pffisfint invention are! p y P p scribed and claimed in US. patent application S.N. 312,- P Y methane; benlldlne; 3,3"dlChIOTO' 320 filed Sept. 30, 1963, now Us. Pat. No. 3,297,785 benzidine; p y Sulfide; granted on Jan. 10, 1967, and in US. patent applica- P11611311 Sulfone; P Y Sulfone; tion S.N. 358,928, filed Apr. 10, 1964, now US. Pat. amino-diphenyl ether; 1,5-diamin0-naphtha1ene; meta- No. 3,312,645, granted on Apr. 4, 1967, which are by phenylenediamine; p Phenylene diamine;

reference incorporated into the present application. m hyl biphenyl d ami 3,3 dimethOXy nZi- These applications relate to polyester resins derived dine; bi$(bela amino y toluene; w from polyfunctional derivatives of isocyanuric acid which y 'p y ether; -(P a-' ta-methyl-delta contain a plurality of alkyl-X groups where X is OH or -p y benzene; -p yln O pentyl)benzene; l-isopropyl-2,4-meta-phenylene diamine; ll m-xylylene diamine; p-xylylene diamine; di(para-amino- COR cyclohexyl)methane; hexamethylene diamine; heptaand where R 1s H or an alcohol moiety, preferably methylene diamine; octamethylene diamine, nonamethyltrls(2-hydroxyethyl) isocyanurate. These polyesters are ene diamine, decamethylene diamine; diamino-propyl prepared from (1) polycarboxylic acids, esters, etc. (2) tetramethylene diamine; 3 methylheptamethylene diglycols and (3) polyols, wherein (1), (2) or (3) are amine; 4,4 dimethylheptamethylene diamine; 2,1l-diaminododecane; 1,2-bis-(3-amino propoxy)ethane; 2,2- dimethyl propylene diamine; 3-methoxy-hexamethylene diamine; 2,5 dimethylhexamethylene diamine; 2,5 dimethylheptamethylenediamine; 3 methylheptamethylene diamine; 5 methylnona-methylenediamine; 2,11 diaminododecane; 2,17 diamino-eicosadecane; 1,4 diamino cyclohexane; 1,10 diamino 1,10 dimethyl decane; 1,12 diamino-octadecane;

H N( CH N(CH )(CH NH piperazine. A plurality of the above polyamines can also be employed, for example 2, 3, 4- or more of these amines, in preparing the polymer.

The tricarboxylic acid is characterized by the formula Cit where is the moiety of the acid.

Although trimellitic acid or its anhydride (TMA) is the preferred embodiment, other suitable tricarboxylic acids or anhydrides can also be employed, for example:

(LO 1 t? LL and the like. Aromatic tricarboxylic acids are preferred.

The polyamide-imide resins can be prepared by a variety of methods. The reaction may be viewed as occurring in stages.

which is further reacted to form the polyamide-imide.

Thus, in essence, the reaction is a condensation reaction yielding amides at the first stages and imides in the second stage. Since water is released during the polymerization condensation, its removal is an index of the progress of the reaction. In general, it is believed that reaction with the anhydride group occurs first, thereupon .amidification occurs with the nonanhydride carboxylic group. These reactions in general occur at lower temperatures. Thereupon as the temperature is raised imidification occurs.

Polyamide-imide resins are prepared by any suitable method. In general, they are prepared by reacting TMA and the diamine under dehydrating conditions, with or without a solvent. Any suitable temperature capable of dehydration can be employed, for example 300400 F. or higher. In gerenal, the higher the temperature the shorter the reaction time. If desired toward the end of polymerization, small amounts of reactive compounds capable of combining with the reactants can be employed to drive the polymerization to completion, for example cyclic alkylene lactams. In general, it is advisable to heat and agitate the reaction mixture until maximum viscosity denoting maximum polymerization is obtained.

The degree of polymerization is subject to deliberate control. The use of equal molar amounts of the reactants under the prescribed conditions provides a very high molecular weight. The use of either reactant in a large excess limits the extent of polymerization, but may be employed if desired.

In general, it is not desirable to employ more than 5% excess of either the diamine or TMA. More than 5% excess of either reactant generally results in undesirably low molecular weight resins. For some purposes, it is desirable to use 13% excess of either reactant, preferably diamine.

The solvents useful in the solution polymerization process for synthesizing the polyamide-imides or as solvents for the products are the organic polar solvents having a dipole moment whose functional groups do not react with the diamines or the TMA. Besides being inert to the system and being a solvent for the product, the organic polar solvent must also be a solvent for at least one of the reactants, preferably for both. Solvents of the N.N-dialkylcarboxylamide class are useful as solvents in the process with the preferred solvents being the lower molecular weight members of this class, in particular N,N-dimethylformamide and N,N-dimethylacetamide. These solvents may be easily removed from the polymer by evaporation, displacement or diffusion. Other typical compounds of this class of solvents are: N,N-diethylformamide, N,N-diethylacetamide, N,N-dimethylmeth0xy aceta'mide, etc. Additional organic polar solvents which may be used in the present invention are: dimethyl-sulfoxide, N-methyl-Z-pyrrolidone, pyridine, dimethylsulfone, hexamethylphosphoramide, tetramethylene sulfone, dimethyltetramethylene sulfone. The solvents can be used alone, in combination of solvents, or in combination with nonsolvents such as benzene, benzonitrile, dioxane, butyrolactone, xylene, toluene, and other polyalkyl benzenes, mineral spirits, cresols, cresylic acid, cyclohexane, etc. However, the addition of water should be avoided and the process should be conducted under essentially anhydrous conditions.

These solvents are also employed in preparing solutions for applications to the wire.

When the polyester base coat and the polyamide-imide over coat resins of the present invention are to be employed as magnet wire enamels, the resins are applied to the wires from solution by well-known methods. For optimum results I have found that solutions containing from about 25 to 40 percent resin solids should be employed. These solutions can be prepared by diluting higher concentration resin solutions with any of the resin solvents mentioned herein, or in the references incorporated herein.

The method of applying both types of resins to wire comprises passing the wire through the resin solution, through a suitable die, and then through an oven maintained at an elevated temperature to cure the resin on the wire. Where desired, the wire may be passed through the resin solution and a die a number of times and through the oven after each pass through the resin solution. This will provide a greater enamel build than is obtainable with only one pass through the resin solution. Although the die sizes are not critical, I prefer to employ dies which provides a clearance of from two to four mils around the wire. The speed at which the wire is passed through the resin solution and the temperature at which the oven is maintained depend on the particular resin solution employed, the build of enamel desired, the length of the oven in which the coated wire is cured, and the molecular weight of the resin used in the coating operation. I have found that a total enamel build on a 40.3 mil or 18 Wire round copper wire of about 3 mils (diameter of enameled wire less diameter of bare wire) may be obtained by passing the wire through a solution containing 25-35%, by weight, of a suitable resin and through a heating tower 18 feet long at speeds of from about 15 to 40 feet per minute when the temperature of the curing oven is maintained at from about 600 F. to 1000 F. In general, the higher the wire speed, the higher is the optimum wire tower temperature. In the coating operation just described, the wire is generally passed through the resin solution and a wire tower as many times as required to obtain the desired build, generally a total of about six times. In addition, the wire can be coated by dip application, groove rolls, etc.

In order to insure complete curing of both types of resins of the present invention when applying them to conductors, it is desirable to employ a curing catalyst to accelerate the curing reaction in the resin solutions during the coating operation, although satisfactory results are obtained without the use of such a catalyst. Among the many curing catalysts suitable for this purpose may be the soluble salts of Zn, Pb, Ti, Cd, Bo, Th, etc., for example zinc octoate, cadmium octoate, copper naphthenate, tetraisopropyl titanate tetrabutyl titanate, etc., blocked aromatic isocyanates, blocked aliphatic isocyanates, may be employed with the polyesters, etc. Where metal-containing curing catalysts are employed I have obtained satisfactory results using from about 0.05 to 3.0 or more percent, by weight, of the metal element of the catalyst based on total resin solids. Preferably, one employs sufiicient metal-containing catalyst to give about 0.1-2.0 percent metal based on the total resin solids.

The build of the over coat in relation to the base coat should be sufiicient to impart the desired properties thereto. For example, the top coat may be about 5% by volume of the total enamel coat, for example -50% or more, such as 1040%, but preferably about 14-25%. Although larger volumes of over coat can be employed, in practice and for economic reasons I employ the minimum amount of over coat capable of imparting the desired properties to the wire. For example, I have satisfactorily employed an over coat layer obtained by one pass through the polyamide-imide resin solution to a base coat layer obtained by 5 to 6 passes through the polyester resin.

The following examples are presented for purposes of illustration and not of limitation.

These base coat resins comprise the reaction of: (1) from about to 56 equivalent percent, preferably from about 36 to 50 equivalent percent of a lower dialkyl ester of terephthalic acid and isophthalic acids and mixtures thereof or their equivalent, (2) from about 15 to 46 equivalent percent, and preferably from about 25 to 40 equivalent percent of ethylene glycol, and (3) from about 13 to 44 equivalent percent of a saturated aliphatic polyhydric alcohol having at least three hydroxy groups.

EXAMPLE 1 A polyester resin is prepared from the following ingredients:

Equivalent percent Dimethyl terephthalate 46 Ethylene glycol 31 Glycerin 23 These ingredients plus xylene are added to a three liter,

three-necked flask, fitted with a thermometer, stirrer, and a five inch Vigreux column. A Dean and Stark trap and an addition funnel are attached to the top of the column and a nitrogen blanket is maintained on the system. The system is heated for 30 minutes, during which time the temperature rises to about 130 C., and water and xylene are azeotropically distilled from the system. At this time about 0.03 percent lead acetate based on the weight of dimethyl terephthalate is added and the heating is continued for three and one-half more hours to a final temperature of about 240 C. Sufficient cresol is then added to the hot resin to form a solution having a solids content of 44.8 percent by weight. A portion of this solution is cut to a solids content of 25 percent with xylene after sufficient zinc octaonoate has been added to give 0.5 percent zinc based on total resin solids. This solution is used to apply the resin to the wire.

Other base coat polyester resins similarly prepared are presented in the following table. DMI is dimethylisophthalate; DMT is dimethylterephthalate.

TABLE I Equivalent Equivalent Equivpercent percent alent dimethyl ethylene percent terephthalate glycol glycerin Example:

2 50 25 25 46 26 28 45 27 28 46 17 37 50 15 35 37 19 44 37 32 31 25 38 37 36 46 18 46 39 15 50 36 14 56 22 22 45 33 22 1 2.3, 1 43.7 31 23 5.8, 2 40.2 31 23 l 9.8, 2 36.2 31 23 l 23, 2 23 31 23 46 31 23 40 4 3 20 46 31 4 20.7, b 2 3 37. 5 37.

1 Dimethylisophthalate. 2 Dimethylterephthalate. 3 1,1, tremethylol ethane. 4 Glycerin. 5 Diglyeorol. 6 Sorbitol.

The following example illustrates the use of blocked isocyanurates in the polyester formulation.

EXAMPLE 23 Mondur SH is gradually added to the polyester resin of Example 1 at IOU- C. over a period of about a half hour at the ratio of 1 part of Mondur SH to 3.5 parts of the polyester and maintained at this temperature for about 1 hour. Tetrabutyl titanate (.05 is added as a curing agent.

The following polyester resins are similarly treated with Mondur SH and applied as base coat wire enamels.

Example 24The polyester resin of Example 2. Example 25-The polyester resin of Example 5. Example 26-The polyester resin Example 8.

9 Example 27--The polyester resin of Example 12. Example 28The polyester resin of Example 16. Example 29-The polyester resin of Example 21.

Base coats of polyesters prepared from tris (2-hydroxyethyl) isocyanurate (THIC) are also employed in this invention such as described in application Ser. No. 312,320

filed Sept. 30, 1963. Specific examples of such resins are The following example illustrates the preparation of a polyamide-imide resin.

Example--Table IH, 6

To a flask equipped with an inert gas inlet, an agitator, a thermometer and a sampling port are charged TMA (10 moles) and m-phenylene diamine (09.8 mole). This mixture is heated to approximately 300 F. and litharge (3.0 g.) is added. Heating is continued until the temperature is slowly raised to approximately 370 F. When the reaction slows down, heat is reduced to about 320 F. and e-caprolactam (lmole) is added and heating continued to a temperature of 370 F. Reaction is terminated by adding solvent (N-methyl pyrrolidone 75% and dimethyl acetamide 25%) when a viscosity of 1600 cps. at 36% concentration in this solvent is reached. This solution is used to apply the resin to the wire as an overcoat.

The following are other specific examples of over coat polyamide-imide resins which can be employed in this in- TABLE II Equivalent Equivalent S .N. percent percent Equivalent 312, 320 dimethyl ethylene percent Weight percent additive Example example phthalate glycol THIC (based on resin) 43. 29. 1O 27. 55 2% melamlne.

43. 35 29. 10 27. 55 2% melamine plus 1% Zn.

43. 35 29. 10 27. 55 3% melam ne.

43. 35 29. 10 27. 55 2% melamine plus 011 0.06.

By way of illustration, Example 41 is prepared in accord with Ser. No. 312,320.

Dimethylphthalate (9.01 moles, 1750.0 g.) and THIC (3.94 moles, 1030.0 g.) are placed in a flask equipped with an inert gas inlet, an agitator and condenser take off and heated to 280 F. Litharge (3.0 g.) is then added and the mixture is heated to 400 F. until a T viscosity at a concentration of 37% in cresylic acid is obtained. Ethylene glycol (5.64 M, 350.0 'g.) is then added and esterification continued at 400 F. until a viscosity of Z3-Z4 is obtained at 31% solids in a solvent which is 60% cresylic acid, 20% Solvesso 100 solvent and 20% Solvesso 150 solvent. This 31% solution is employed in applying the resin to the wire.

Oil modified polyester resins can also be employed, for example the oil-modified polyesters described in US. Pat. 2,905,650, for example, Example 1 thereof derived from dimethyl phthalate 2.0 M, ethylene glycol 2.2 m, glycerine 0.377 M and soya oil 0.189 M; and also the oil modified THIC resins disclosed in application Ser. No. 358,928.

Other examples of polyester resins which can be employed as a base coat can be found in the following US. Patents: 2,686,739 (Silicone modified). 2,686,740 (Silicone modified), 2,687,396 (Silicone-epoxy-phenol resins modified); 2,687,398 (Silicone-epoxy-modified), and 2,686,740 (Silicone modified).

The above polyester resins are employed to base coat round copper wire. In most instances the resin is applied by passing the conductor through the resin solution, a suitable die, and a vertical wire tower at a wire speed of 20-40 ft./min. at 600-800 F. with 3-6 passes being employed to obtain the final base coat build, but preferably 5 passes.-

The over coat polyamide-imide resin'is similarly applied to the cured polyester wire enamel resulting in a base polyester coat and an overcoat of polyamide-imide resin. It is generally applied in 1-3 passes to obtain the final overcoat build, but preferably 1 pass.

The total build is usually about 3 mils such as 2.9-3.2 mils.

vention. They are prepared in the manner of Example, Table III, 6, both with or without the caprolactam.

TABLE HI-Polyrner unit 0 where X is a halogen, i.e. chlorine, bromine, etc. A1-

ll though phthalic acids are preferred, other carboxylic acids can be employed, for example,

I] N o 0 1 ll kc- CH2 CX l i i if Xos CX H 3 i(I 0 etc. 15 These compounds may also be prepared by reacting an aromatic acid halide, such as a diacyl halide or a nitroacyl halide, with a substantially stoichiometric amount of A polyamide-imide resin characterized by the polymeric a suitable compound for example a nitro-amine or a priunit of Table III, 6 is currently being produced cornmary aromatic diamine. The nitro aromatic compound is mercially. reduced, as for example by hydrogenation, to the corre- One class of polyamines useful in preparing the polysponding diamino aromatic compound. amide-imide resin of this invention are those polyamines These reactions are illustrated by the following equawhich contain at least one amido unit within the R group. tions:

These are formed by reacting any of the above diamines, NH R'NH with the appropriate carboxylic acid or its 0 0 equivalent, preferably an aromatic carboxylic acid, and 5 P; most preferably a phthalic acid such as an ortho-, meta- (iso), orhpkarla-(terei) ph:halic, bu1t preferably a metao; H a H H H a terep t a to am or 1 s equiva ent. n practlce an act 2 halide is employed, for example O 40 II o o 11 0 O ll ll Direct reaction, without hydrogenation, is illustrated by the following reactions:

III. ci aa NHP a NEE h Three amide-containing diamines can be employed to o 0 prepare polyamide-imide resins of the formula II I] o x0- x g at 15 \WnL C II 0 n m 0 o o i O" H H CNR-NG where R is, for example,

Where the polyamine has a plurality of amido groups, the resulting polymer is a block polymer, whether prepared (1) by reacting the diacyl halide with an aminoterminated polyamide-imide or (2) by reacting a diamino- C 00 NH polyamide with TMA; Stated another way the polymer is I 0- n J characterized by distinct polyamide units and distinct polyamide-imide units.

in which X represents an integer of from 1 to 500. Co- Thus, these p lym rs are prepared '(A) by reacting at polymers, comprising two or more of these R groups, least one amide or polyamide having two terminal primary have been found to be especially valuable in some cases. aromatic amino groups with trimellitic anhydride or its Corresponding R's can also be derived from the other equivalent, or (B) reacting at least one primary aromatic diamines, NH tR'-NH described herein. diamine with trimellitic anhydride and then reacting this In addition, a polymer can be prepared by first reacting product having terminal amino groups with at least one 'TMA 'with an excess of diamine to yield an amino-termiaromatic dibasic acid halide.

nailed p i and then reading this Product With the y The following examples are presented by way of illushalide. This 1s illustrated by the following equation: t io d t f li it tio EXAMPLE A H O NR--NH2 NHzR-N A C polymer 1s prepared by reacting m-phenylene diamme H with terephthaloyl chloride in dimethylacetamide with a 0 n triethyl amine present at 35-40 C.

A polymer of the following formula is formed:

The diamine polymer of Example A is reacted with TMA at 300400 F. to form a polyamide-imide presented by the following idealized formula: 10

EXAMPLE C This example illustrates the preparation of a diamino polyamide-imide and subsequent reaction with an aromatic diacid chloride.

A solution of an excess of m-phenylene diamine in dimethylacetamide is stirred while TMA is added and polymerized. Triethylamine is added thereto. This solution is stirred rapidly while isophthaloyl chloride is added thereto to form the desired polymer, which is a block 30 polymer containing both polyamideimide and polyamide block units.

These polymers are useful as wire coatings, molding and laminating resins, films for electrical insulating or mechanical use, varnish components, etc. In addition, they 3 can be employed as an overcoat in accord with this invention.

The following Table IV very clearly illustrates the superiority of the present invention which employs a base polyester coat and a polyamide-imide over coat. The base 40 coat applied is the resin described in Example 41 of this application, Table II, and the over coat is the Amoco Chemical Co. 1A type 10 Resin which is a commercial polyamide-imide resin. Both resins are coated and cured in the conventional manner employing a coating die and 45 a wire tower. The volume ratio of base coat to over coat is 5 to l, i.e. 5 passes of the polyester to 1 pass of the polyamide-imide resin. The combination of resins is superior to each individually.

TABLE IV AMOCO 1A Type 10 resin ner, other polyester base coats and other polyamide-imide over coats can also be employed in the present invention. For example, any of the polyester resins applied as base coats and any of the polyamide-imide resins applied as top coats described herein also produce an improved electrical conductor. Thus, the base polyester resins of Table I are employed in conjunction with the polyamide-imide resins of Table III in volume ratios of 5:1, polyester to polyamide-imide.

Although the invention has been illustrated by application to a wire of the magnet wire type, it should be understood that it can also be applied to other materials where such a combination of coatings yield an improved product.

As is quite evident, polyesters and polyamide-imide resins will be constantly developed which could be useful in this invention. It is, therefore, not only impossible to attempt a comprehensive catalogue of such compositions, but to attempt to describe the invention in its broader aspects in terms of specific chemical names of the components used would be too voluminous and unnecessary since one skilled in the art could by following the description of the invention herein select a useful polyester and a polyamide-imide resin. This invention lies in the use of suitable polyesters and polyamide-imide resins in conjunction with electrical conductors and their individual compositions are important only in the sense that their properties can affect this function. To precisely define each specific useful resin in light of the present disclosure would merely call for knowledge within the skill of the art in a manner analogous to a mechanical engineer who prescribes in the construction of a machine the proper materials and the proper dimensions thereof. From the description in this specification and with the knowledge of a chemist, one will know or deduce with confidence the applicability of specific polyester and polyamide-imide resins suitable for this invention. In analogy to the case of a machine, wherein the use of certain materials of Combination polyester base coat (5 volumes) AMOCO 1A, Type 10 top coat (1 volume) Oven temp 680 F Wire speed 35 ft smoothness... Sandy and grainy Snap plus 1X Poor Adherence Elongation. Elongation plus 1X Scott t\vist Tesla blow test G.E. abrasion... Cut thru F. potentiometer Emerson scrape Heat aged 1 hr. at 300 C. unstretched O 15% elongated 1 hr. 300 C Fails lXD; OK 2XD.

Exact nlandreL Snap Boil, l-toluol,1-alcohol From the above Table IV it is quite evident that when applied to an electrical conductor a polyamide-imide resin is unexpectedly improved by a polyester base coat in combination with a polyamide-imide over coat. In like man- 35%. OK IXD.

I28. 4 breaks at 10ft.

(700g.) 102. 679 F. 11,500 v.

32 pounds.

OK lXD; OK 2XD; OK

Fails lXD; OK 2XD;

OK 3XD.

OK 30 min.

construction or dimensions of parts would lead to no practical useful result, various materials will be rejected as inapplicable where others would be operative. I can obviously assume that no one will wish to use a useless polyester resin or a useless polyamide-imide resin nor will be misled because it is possible to misapply the teachings of the present disclosure to do so. Thus, any polyester resin or polyamide-imide resin that can perform the functions stated herein can be employed.

As employed herein, tricarboxylic acids and trimellitic acid, etc. relate to the acids or anhydrides themselves and derivatives thereof such as esters, acyl halides, anhydride-acyl halides, anhydride-esters, etc. which can be reacted to yield the same, similar or analogous products, for example where X is a halide, e.g. chloro, bromo, etc.,

I O RO-Jilwhere R is an alcohol moiety. Stated another way, this invention includes the specific reactants or derivatives thereof which can be employed in place of the stated reactants to yield the same, similar or analogous products. In addition, it should be understood that intermediates may also be formed which on further reaction yield the polyamide-imides of this invention, for example which on further reaction yields the imide-amide o o mr and copolymers thereof, in which x is an integer of from 20 1 to about 500. OH

2. The polya'mide-irnide resin of claim 1 wherein the H 0 polymeric unit is l H Q NCO C-NR- Ill OH and I H li-0rr +0 i t r -@-fi-@ 0 0 0 H 4. The precursor of claim 2 which is a polyamide-acid 3. l l 'd The Precursor of c mm 1 whlch 1S a P0 e acld consisting essentially of the recurring structural unit consisting essentially of the recurring structural unit selected from the group consisting of oH 1 ,0 M H O I I CNR- O H 5. The polyamide-imide resin of claim 2 wherein the H repeating polymeric unit has the formula H t l N/ N C i 0 6. An insulated electrical conductor having as insula- Il tion on the conductor the polyamide-imide resin of HO-C 0 H claim 1. R, C II 7. An insulated electrical conductor havin as insula- N tion on the conductor the polyamide-imide resin of H 0 claim 2.

0 o H 8. An insulated electrical conductor having as insulag l tion on the conductor the polyamide-imide resin of claim 5.

R E References Cited 0 UNITED STATES PATENTS E 5 3,049,518 8/1962 Stephens 26078 H O 3,179,635 4/1965 Frost et al. 26078 g 3,260,691 7/1966 Lavin et al. 26030.2. ---ff f 3,428,486 2/1969 George 1172l8 O H 0 WILLIAM H. SHORT, Primary Examiner l-0H L. L. LEE, Assistant Examiner Notice of Adverse Decision in Interference In Interference No. 98,578, involving Patent No. 3,554,984, N. J. George, POLYAMIDE-IMIDE RESINS, final udgment adverse to the patentee was rendered Aug. 6, 1974, as to claims 1 and 6.

[Official Gazette December 24, 1974.] 

